Charcoal Starting Device and Method

ABSTRACT

A charcoal igniting device includes an envelope, a chimney, and a base. The envelope has an envelope height and an envelope width, the envelope height is greater than the envelope width. The envelope sidewall defines a series of holes. The envelope has an upper envelope rim and a lower envelope rim. The chimney is disposed co-axially within the envelope. The chimney has a sidewall impregnated with wax, an upper chimney rim, an ignition element disposed upon the upper chimney rim, and a lower chimney rim. The base defines a series of holes disposed through the base. The base has an outer base perimeter mated to the lower envelope rim and an inner base perimeter mated to the lower chimney rim.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Continuation-In-Part Application and claims priority to U.S. patent application Ser. No. 12/117,481, filed on May 8, 2008, titled “CHARCOAL STARTING DEVICE AND METHOD”, the disclosure of which is incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

The present invention generally relates to a charcoal ignition device. More particularly, the present invention pertains to a device for storing and ignition of charcoal and a method of fabricating the device.

BACKGROUND OF THE INVENTION

It is generally known that charcoal is utilized as a fuel source for cooking or grilling foodstuffs. Typically, a supply of charcoal is placed on a grating of a grill and ignited. Once the charcoal has formed uniformly alighted coals, the foodstuffs may be grilled. To accelerate ignition, conventional charcoal may include various flammable waxes and/or petroleum distillates. However, even with these accelerants, rapid coal formation is not guaranteed. In addition, rapid, even coal formation is typically facilitated by stacking the charcoal in a pile. Unfortunately, charcoal is generally dusty and this very dark or black dust may be messy or otherwise objectionable to some individuals. Accordingly, it is desirable to provide a device for igniting charcoal that is capable of overcoming the disadvantages described herein at least to some extent.

SUMMARY OF THE INVENTION

The foregoing needs are met, to a great extent, by the present invention, wherein in some embodiments device for igniting charcoal is provided.

An embodiment of the invention pertains to a charcoal igniting device. The charcoal igniting device includes an envelope, chimney and base. The envelope has an envelope height and an envelope width. The envelope height is greater than the envelope width. The envelope includes an envelope sidewall defining a series of holes, an upper envelope rim, and a lower envelope rim. The chimney is disposed co-axially within the envelope. The chimney includes an n-faceted sidewall impregnated with wax, an upper chimney rim, an ignition element disposed proximate the upper chimney rim, and a lower chimney rim. The base is defined by a series of holes. The base has an outer base perimeter mated to the lower envelope rim and an inner base perimeter mated to the lower chimney rim.

Another embodiment of the invention relates to an improved charcoal igniting device. The improved charcoal igniting device includes a container, chimney, and base. The container has a container sidewall, an upper container rim, and a lower container rim. The chimney is disposed co-axially within the container. The chimney has a chimney sidewall, an upper chimney rim, and a lower chimney rim. The base is defined by an outer base perimeter mated to the lower container rim and a centrally located orifice having an edge mated to the lower chimney rim. A container volume is defined by the container sidewall, the base, and an exterior surface of the cone sidewall. The improvements of the charcoal igniting device include a series of holes defined by the container sidewall to facilitate an ingress of air therein. The chimney is an n-faceted frustum and a plurality of tabs and corresponding mating slots are included to retain an assembled shape of the container and chimney. In addition, the improved charcoal igniting device includes a supply of wax impregnated in the chimney sidewall to provide a fuel to ignite the supply of charcoal and an ignition element disposed on the upper chimney rim. In response to ignition of the ignition element, the wax impregnated chimney sidewall burns and draws air upwardly through the chimney and inwardly and upwardly through the series of holes in the container sidewall, and a flame front proceeds in an inverted cone downwardly through the container volume.

Yet another embodiment of the invention pertains to a method of fabricating a charcoal igniting device. In this method, an envelope is generated from a envelope pattern. The envelope includes mating tabs and corresponding slots to retain the envelope in an assembled shape. An n-faceted frustum is generated from a frustum pattern. The frustum includes an ignition element disposed at an upper opening of the frustum. The frustum is infused with wax. A bottom panel is affixed to the envelope. The bottom panel includes an outer diameter corresponding to a bottom rim of the envelope. The bottom panel includes an inner orifice having a diameter corresponding to a width of a lower rim of the frustum. The lower rim of the frustum is affixed to the inner orifice of the bottom panel.

There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto.

In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.

As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a hidden line, perspective view of a charcoal igniting device according to an embodiment of the invention.

FIG. 2 is an exploded view of the charcoal igniting device according to an embodiment of the invention.

FIG. 3 is a plan view of the pre-cut and pre-scored blanks suitable for use in the charcoal igniting device according to an embodiment of the invention.

FIG. 4 is a cross sectional view of the charcoal igniting device during the ignition process according to an embodiment of the invention.

FIG. 5 is a perspective view of the charcoal igniting device according to an embodiment of the invention.

FIG. 6 is a plan view of the pre-cut and pre-scored blanks suitable for use in the charcoal igniting device according to another embodiment of the invention.

FIG. 7 is an exploded view of the charcoal igniting device according to the embodiment of FIG. 6.

DETAILED DESCRIPTION

The present invention provides, in some embodiments, a charcoal starting or igniting device and a method of fabricating the charcoal igniting device. In general, the charcoal igniting device includes an envelope or container configured to retain a supply of charcoal. For the purpose of this disclosure, an envelope is defined as a structure to enclose or partially enclose a space, volume, or item. This envelope includes a fiber-based sheet stock such as, for example, fiberboard, corrugated fiberboard, and the like. For the purpose of this disclosure, the term, “fiberboard” is defined as at least including, for example, paper, paperboard, cardboard, corrugated cardboard, cellulosic, and/or resinous material which is similar in character to fiberboard, and which is manipulated in the same or similar manner as fiberboard. This includes any suitable material capable of being folded from a blank. In this regard, the term “blank” refers to at least a piece or unit of fiberboard that is cut or scored and/or suitable for folding into a particular conformation such as a box, base, cone, lid, or tube.

In another embodiment, the invention provides for a method of fabricating the charcoal igniting device. In this method, the various components of the charcoal igniting device may be assembled and packaged for storage, transport, and sales.

The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. As shown in FIG. 1, a charcoal ignition device 10 includes an outer container or envelope 12, chimney 14, and base 16. Together, these components define a volume suitable for retaining a supply of charcoal 18.

The envelope 12 is optionally cylindrical in shape and is relatively taller than it is wide. The envelope 12 may be fabricated from any suitable sheet good. In a particular example, the envelope 12 may be fabricated from paperboard or the like. The envelope 12 includes a set of holes or vents 20 disposed at or near a lower rim of the envelope 12. As described herein, the vents 20 provide for an ingress of air to provide oxygen for the burning charcoal 18.

In various examples, the set of vents 20 may include one or more individual vents. The vents may be round or rounded, square, rectangular, polygonal, or the like. Generally, the set of vents 20 are sized and shaped to reduce the likelihood that the charcoal will spill out therefrom. The set of vents 20 may be arranged about the circumference of the envelope 12 in one or more rows.

In various embodiments the chimney 14 includes a frusto-conical structure or frustum of a pyramid and generally tapers from a relatively wide base to a relatively more narrow upper rim. As used herein, the term a ‘frustum’ and its derivatives refers to a portion of a cone or n-sided pyramid disposed between two planes intersecting the cone or pyramid. The chimney 14 includes the side surface(s) of the frustum and may be open at the top and/or bottom.

The chimney 14 serves as a conduit or conveyance device to draw air from below the charcoal ignition device 10 and bring fresh, oxygenated air into the interior of the charcoal ignition device 10. The chimney 14 may be fabricated from any suitable sheet good. In a particular example, the chimney 14 may be fabricated from paperboard or the like. In addition, this paperboard cone may be infused or coated in a fuel or accelerant such as wax, resin, petroleum distillate, or the like. In a particular example, the cone is infused with paraffin wax. The chimney 14 optionally includes a wick or ignition element 22 disposed on or proximate to the upper rim. If included, the ignition element 22 provides a device or convenient location to initiate ignition of the charcoal ignition device 10. Alternatively, the upper rim of the chimney 14 may be lit directly to initiate ignition.

The base 16 is generally shaped as an annular disk and provides a bottom panel that connects the bottom rim of the envelope 12 to the bottom rim of the cone 16. The base 16 may include any suitable sheet good. In a particular example, the base 16 may be fabricated from paperboard or the like. Optionally, the base 16 includes a set of bottom openings or vents 24. If included, the set of bottom vents 24 provide for an ingress of air to provide oxygen for the burning charcoal 18.

In various examples, the set of bottom vents 24 may include one or more individual vents. The vents may be round or rounded, square, rectangular, polygonal, or the like. Generally, the set of bottom vents 24 are sized and shaped to reduce the likelihood that the charcoal will spill out therefrom. The set of bottom vents 24 may be arranged in a circular or other such pattern upon the base 16.

FIG. 2 is an exploded view of the charcoal igniting device 10 according to an embodiment of the invention. As shown in FIG. 2, the various components of the charcoal igniting device 10 may include a plurality of tabs 26 to provide bonding surfaces. In a particular example, the lower rim of the envelope 12 and the lower rim of the chimney 14 may include the tabs 26 to facilitate bonding to the base 16. In this regard, the base 16 may include an inner base 16A and an outer base 16B. The tabs 26 may be sandwiched between the inner base 16A and outer base 16B to provide greater bonding strength.

To generate the bond, an adhesive may be applied to the tabs 26 and/or to one or both of the inner base 16A and outer base 16B. With the tabs 26 disposed between the inner base 16A and outer base 16B, the inner base 16A and outer base 16B may be urged together and held thusly until the adhesive sets.

Also shown in FIG. 2, the wick 22 may include a plurality of wicks 22 a. In a particular example, a series of cuts may be made into the upper rim of the chimney 14 to generate a series of wicks 22 a circumscribing the upper rim of the chimney 14. More particularly, a series of eight cuts may be made about the circumference of the upper rim of the chimney 14. The resulting tabs are configured to provide a relatively greater surface area that is made available to ignite the charcoal igniting device 10. To further facilitate ignition, one or more of the wicks 22 a may be folded outwardly. Optionally, an accelerant may be added to one or more of the wicks 22 a. In a particular example, an end user may place a wax, petroleum distillate, or other such accelerant on or around the wicks 22 s to facilitate ignition.

FIG. 3 is a plan view of a pre-cut and pre-scored blank suitable for use in the charcoal igniting device 10 according to an embodiment of the invention. As shown in FIG. 3, the blank for the envelope 12 may include a strip of paperboard that is rolled upon itself to generate a cylinder. Adhesive may be applied to all or a portion of the blank to affix the envelope 12. In a particular example, the adhesive may be applied to one or more gluing areas 28. In addition, to generate a uniform diameter, the blank for the envelope 12 may be wrapped around a form (not shown).

Similarly, the blank for the chimney 14 may include the gluing areas 28 for the application of the adhesive. The blank for the chimney 14 may also be wrapped around a form (not shown) to generate a consistently sized component. Subsequently, the formed chimney 14 may be immersed in wax or other such accelerant to infuse the accelerant therein.

FIG. 4 is a cross sectional view A-A of the charcoal igniting device 10 during the ignition process according to an embodiment of the invention. As shown in FIG. 4, following ignition of the ignition element 22, a flame 30 proceeds downwardly via the wick towards the chimney 14. During an initial phase, a flame front proceeds through the volume of charcoal as indicated by the region 32. That is, flame 30 proceeds further downwardly along the chimney 14 and outwardly into the supply of charcoal 18 in a generally inverted cone shape. It is an advantage of embodiments of the charcoal igniting device 10 that the envelope 12 remains largely or entirely unconsumed during the initial and into an intermediate phase. During this intermediate phase, the flame front proceeds through the volume of charcoal as indicated by the region 34. In this manner, the supply of charcoal 18 remains confined within the charcoal ignition device 10 and is therefore more likely to ignite. In contrast, if the envelope 12 were to ignite during the initial phase, the structural integrity of the envelope 12 may be compromised and the supply of charcoal 18 may fall from the charcoal ignition device 10 without first being ignited.

During a later phase the flame front proceeds through the volume of charcoal as indicated by the region 36 and the envelope 12 is largely consumed by the flame 30. However, the consumption of the chimney 14 may progress relatively faster and thereby increases the likelihood that the supply of charcoal 18 will fall inwardly. This inward settling of the supply of charcoal 18 consolidates the supply of charcoal 18 and facilitates rapid, even coal combustion development. Also shown in FIG. 4, the chimney 14, set of vents 20, and set of bottom vents 24 provide a supply of fresh, oxygenated air to the flame 30 as indicated by flow lines 38.

FIG. 5 is a perspective view of the charcoal igniting device 10 according to an embodiment of the invention that is wrapped or covered in a wrapper 40. In general, the wrapper 40 provides an envelope to retain the supply of charcoal 18 and any dust from the supply of charcoal 18. In addition, the wrapper may provide a surface upon which to place a label. Also shown in FIG. 5, the wrapper 40 may include a handle 42. The handle 42 may provide a ready surface to grasp and carry the charcoal ignition device 10. In a particular example, the handle 42 may include a flat or storage conformation and a carrying conformation.

The wrapper 40 may further include a tear strip 44 configured to facilitate tearing the wrapper 40 open. For example, the tear strip 44 may include a string disposed below the wrapper 40. By pulling on the tear strip 44, the wrapper 40 may be torn about the circumference of the charcoal ignition device 10. Thereafter, the wrapper 40 may easily be removed in preparation for ignition.

FIG. 6 is a plan view of a pre-cut and pre-scored blank suitable for use in the charcoal igniting device 10 according to another embodiment of the invention. As shown in FIG. 6, the blank for the envelope 12 may be fabricated using one or more sheets 50 of fiberboard. In a particular example, two sheets 50 of fiberboard are used as stock to die cut the various components of the charcoal igniting device 10. In the particular example illustrated in FIG. 6, the charcoal igniting device 10 includes a first envelope portion 12A and a second envelope portion 12B and the inner base 16A that are cut as a single piece. The charcoal igniting device 10 also includes a chimney 14′ and outer base 16B.

Also shown in FIG. 6, rather than gluing areas 26 as shown in FIG. 3, the first envelope portion 12A and second envelope portion 12B and chimney 14′ include tabs 52A-52E configured to mate with slots 54A-54E. In this or other embodiments, the chimney 14′ may include one or more openings 56 to allow the tab 52E to pass through the chimney 14′ to engage or mate with the slot 54E. In this regard, to assemble the chimney 14′, the blank for the chimney 14′ is folded at score lines 58A to 58N starting at end 60, rolling the blank of the chimney 14′ upon itself, and proceeding towards end 62. As the chimney 14′ is folded along the score line 58A to 58 n, the openings 56 may be aligned to provide an opening from the outside of the cone to the inside. Of note, the chimney 14′ fabricated using the blank as shown in FIG. 6 may be shaped as or defined an n-faceted frustum of a pyramid. In a particular example, the chimney 14′ may include a frustum of a hexagonal pyramid with 6 facets or sides. The chimney 14′ may include one or more of the tabs 26 to facilitate securing the chimney 14′ to the base 16 or between the inner base 16A and the outer base 16B. As described herein, some or all of the chimney 14′ may be coated in wax or other such flammable material. In a particular example, an upper 70% to 95% of the chimney 14′ may be immersed in a container of hot, liquid paraffin wax, removed from the container, and aloud to cool and harden. In another example, liquidus wax may be applied via a brush or other such applicator. Optionally, another layer of fiberboard, paper, release coating, powder and/or membrane may be applied to the chimney 14′ to serve as a barrier configured to reduce or prevent stacked charcoal igniting devices from sticking to one another.

To assemble the charcoal igniting device 10, the blank for the first envelope portion 12A and second envelope portion 12B and the inner base 16A may be removed from the sheet 50 and folded along a plurality of score lines 64. The tabs 52A and 52B of the first envelop portion 12A may be inserted into the corresponding slots 54A and 54B of the second envelop portion 12B. The tabs 52C and 52D of the first envelop portion 12A may be inserted into the corresponding slots 54C and 54D of the second envelop portion 12B. The tabs 26 of the first and second envelop portions 12A and 12B may be folder at score lines 66. A sufficient amount of glue may be placed upon one or both of the tabs 26 and inner base 16A to affix the tabs 26 to the inner base 16A. The chimney 14′ is assembled as described above and the tabs 26 are folded at corresponding score lines 58. The chimney 14′ may be inserted up through the central opening of the inner base 16A until the tabs 26 of the chimney 14′ rest upon the inner base 16A. Alternatively, the tabs 26 of the cone 16A may be inserted down through the inner base 16A and then the tabs 26 of the chimney 14′ may be pressed outward to rest upon the inner base 12A. The tabs 26 of the chimney 14′ may be affixed to the inner base 12A with a sufficient amount of glue.

Glue may be placed on one or both of the inner base 16A or outer base 16B and the inner base 16A and outer base 16B may be affixed together while sandwiching the tabs 26 of the first and second envelop portions 12A and 12B and the chimney 14′ therebetween. As described herein, the supply of charcoal 18 (shown in FIG. 1) may be placed in the charcoal igniting device 10. In addition, the wrapper 40 (shown in FIG. 5) may be used to cover the charcoal igniting device 10.

FIG. 7 is an exploded view of the charcoal igniting device according to the embodiment of FIG. 6. The FIG. 7 is similar to the FIG. 2 and thus, for the sake of brevity, those elements already described hereinabove will not be described again. As shown in FIG. 7, the container 12 is retained in shape via the action of the tabs 52A-52D disposed in the respective slots 54A-54D. Also shown in FIG. 7, the outer base 16B is integrated into or unitary with the container 12.

The particular chimney 14′ shown in FIG. 7 is in the form of a frustum of a hexagonal pyramid. It is an advantage of this and other embodiments that faceted sidewalls of the chimney may facilitate an ease of assembly. The chimney 14′ includes a plurality of tabs 26 to provide bonding surfaces to secure the chimney 14′ to the outer base 16B and/or the inner base 16A. In a particular example, the tabs 26 may be sandwiched between the inner base 16A and outer base 16B to provide greater bonding strength.

Also shown in FIG. 7, a central axis of the container 12 and a central axis of the chimney 14′ are aligned. That is, in this and/or other embodiments, the container 12 and chimney 14′ are co-axial or co-axially aligned.

The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. 

1. A charcoal igniting device comprising: an envelope having an envelope height and an envelope width, the envelope height being greater than the envelope width, the envelope having; an envelope sidewall defining a series of holes; an upper envelope rim; and a lower envelope rim; a chimney disposed co-axially within the envelope, the chimney having; an n-faceted sidewall impregnated with wax; an upper chimney rim; an ignition element disposed proximate the upper chimney rim; and a lower chimney rim; and a base defining a series of holes, the base having an outer base perimeter mated to the lower envelope rim and an inner base perimeter mated to the lower chimney rim.
 2. The charcoal igniting device according to claim 1, wherein the chimney is shaped as a frustum of a hexagonal pyramid.
 3. The charcoal igniting device according to claim 1, wherein the chimney includes a fiber-based paperboard.
 4. The charcoal igniting device according to claim 1, further comprising an envelope volume defined by an interior of the envelope sidewall, an upper surface of the base, and an exterior surface of the sidewall, wherein in response to ignition of the ignition element, the wax impregnated sidewall burns and draws air upwardly through the chimney and inwardly and upwardly through the series of holes in the sidewall and wherein a flame front proceeds in an inverted cone downwardly through a supply of charcoal disposed in the envelope volume.
 5. The charcoal igniting device according to claim 4, wherein the supply of charcoal is about 0.5 kilograms (Kg) to about 4 Kg.
 6. The charcoal igniting device according to claim 1, wherein the chimney further comprises: a tab; a slot to receive the tab; and an opening configured to allow the tab to pass through the sidewall.
 7. The charcoal igniting device according to claim 1, further comprising: a wrapper encasing the envelope.
 8. The charcoal igniting device according to claim 7, further comprising: a handle disposed on an upper surface of the wrapper, the handle having a storage conformation being in a plane substantially parallel to a plane described by the upper envelope rim.
 9. The charcoal igniting device according to claim 7, further comprising: a tear away opener to release the wrapper from the envelope.
 10. The charcoal igniting device according to claim 1, wherein the ignition element includes a series of slits cut into the upper chimney rim.
 11. In a charcoal igniting device comprising: a container, the container having a container sidewall, an upper container rim, and a lower container rim; a chimney disposed co-axially within the container, the chimney having a chimney sidewall, an upper chimney rim, and a lower chimney rim; a base defining: an outer base perimeter mated to the lower container rim; and a centrally located orifice having an edge mated to the lower chimney rim, wherein a container volume is defined by the container sidewall, the base, and an exterior surface of the cone sidewall; the improvement comprising: a series of holes defined by the container sidewall to facilitate an ingress of air therein; wherein the chimney is an n-faceted frustum; a plurality of tabs and corresponding mating slots to retain an assembled shape of the container and chimney; a supply of wax impregnated in the chimney sidewall to provide a fuel to ignite the supply of charcoal; and an ignition element disposed on the upper chimney rim, wherein in response to ignition of the ignition element, the wax impregnated chimney sidewall burns and draws air upwardly through the chimney and inwardly and upwardly through the series of holes in the container sidewall, and a flame front proceeds in an inverted cone downwardly through the container volume.
 12. The improved charcoal igniting device according to claim 11, wherein the chimney includes a fiber-based paperboard.
 13. The improved charcoal igniting device according to claim 11, wherein the chimney includes a frustum of a hexagonal pyramid.
 14. The improved charcoal igniting device according to claim 11, wherein the supply of charcoal is about 1 Kg to about 2 Kg.
 15. The improved charcoal igniting device according to claim 11, further comprising: a wrapper incasing the outer container.
 16. The improved charcoal igniting device according to claim 15, further comprising: a handle disposed on an upper surface of the wrapper, the handle having a storage conformation being in a plane substantially parallel to a plane described by the upper container rim.
 17. The improved charcoal igniting device according to claim 15, further comprising: a tear away opener to release the wrapper from the outer container.
 18. The improved charcoal igniting device according to claim 11, further comprising: a series of holes disposed through the base to facilitate an ingress of air into the container volume.
 19. The improved charcoal igniting device according to claim 11, wherein the ignition element includes a series of slits cut into the upper chimney rim.
 20. A method of fabricating a charcoal igniting device, the method comprising: generating an envelope from a envelope pattern, the envelope including mating tabs and corresponding slots to retain the envelope in an assembled shape; generating an n-faceted frustum from a frustum pattern, wherein the frustum includes an ignition element disposed at an upper opening of the frustum; infusing the frustum with wax; affixing a bottom panel to the envelope, the bottom panel including an outer diameter corresponding to a bottom rim of the envelope, the bottom panel including an inner orifice having a diameter corresponding to a width of a lower rim of the frustum; and affixing the lower rim of the frustum to the inner orifice of the bottom panel.
 21. The method according to claims 20, further comprising: inserting a plurality of tabs into a corresponding plurality of slot to retain the envelope in a predetermined shape.
 22. The method according to claim 20, further comprising: filling the charcoal igniting device with charcoal.
 23. The method according to claim 22, further comprising: incasing the filled charcoal igniting device with a wrapper. 